Davis-Standard, LLC

Checkpoint Installs Integrator C for Better Line Performance

A recent Integrator C control system installation has improved efficiencies for the Checkpoint Systems, Inc. facility in Ponce, Puerto Rico. The Integrator C,
installed last summer, replaced an existing CMR supervisory control system on a 20-year-old
extrusion/lamination line. Since the install, Checkpoint has benefited from the intuitive operator
interface and reduced downtime, which is critical for the company’s high output business.

Checkpoint is the world’s leading provider of radio frequency (RF) based loss prevention
systems for the global retail industry. The company’s facility in Ponce manufactures a variety of
radio frequency tags used for article surveillance.
“The installation of the Integrator went well. After a couple of weeks of fine-tuning and learning new parameters, our results were equal or better than with the CMR,” said Luis Alvarado, Manufacturing Engineer at Checkpoint’s Ponce facility. “This system has a lot more features and gives us the flexibility to do software upgrades and troubleshooting remotely, which reduces our downtime.”

The Integrator C is a direct replacement for the EGAN CMR supervisory control unit. It is a single-point control system that provides the functionality of the CMR while greatly enhancing
many features such as recipe management, historical data trending and alarms. The Integrator C also features a new PLC drives interface, improved temperature controls and enhanced gauge control based on the age of the existing gauge system.
Along with the CMR replacement, Checkpoint also purchased a new drive system from Davis Standard. Converters have multiple replacement options to best accommodate system
requirements and budget parameters. The first option includes a DC drives only upgrade that re-uses the existing motors. The second option includes an upgrade to AC drives and motors,
which equates to increased savings in the long run.

For machines with PLC’s older than 15 to 20 years, several upgrades are available to
improve machine performance, minimize downtime and provide added process control
capabilities based on the converting application. Modern HMI technology allows the operator easy access to set points and process data from multiple locations along the machine.

In the case of Checkpoint, the system was customized to handle the complexity of the
company’s product. Davis-Standard worked with another vendor, NDC Infrared Engineering, to ensure that all software and equipment was functioning in concert with the new system.
According to Alvarado, the machine stabilized much more quickly with the Integrator C than when the CMR was first used. He also appreciated Davis-Standard’s support throughout the
process.

For more information about Checkpoint, visit www.checkpt.com. For more information
about replacing an existing CMR system with the Integrator C, contact Frank Orsini at
orsinif@bc-egan.com.
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